COMPOSITE MATERIALS FOR ELECTROCHEMICAL STORAGE

• US 20110177393A1
• Filed: 01/18/2011
• Published: 07/21/2011
• Est. Priority Date: 01/18/2010
• Status: Active Grant

• Current Assignee: Enevate Corp.
• Original Assignee: Enevate Corp.
• Inventors: TURON TEIXIDOR, GENIS, SCHANK, WILLIAM, PARK, BENJAMIN, ZAOUK, RABIH, STEFFENS, LOTHAR, GORKOVENKO, ALEXANDER
• Granted Patent: US 9,178,208 B2
• Time in Patent Office: Days
• US Class Current: 429/231.8
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C04B 2235/422 Carbon
• CPC Class Codes: C04B 2235/425 Graphite
• CPC Class Codes: C04B 2235/428 Silicon
• CPC Class Codes: C04B 2235/48 Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins
• CPC Class Codes: C04B 2235/5248 Carbon, e.g. graphite
• CPC Class Codes: C04B 2235/5288 Carbon nanotubes
• CPC Class Codes: C04B 2235/80 Phases present in the sintered or melt-cast ceramic products other than the main phase
• CPC Class Codes: C04B 35/522 Graphite C04B35/536 takes precedence
• CPC Class Codes: C04B 35/524 obtained from polymer precursors, e.g. glass-like carbon material
• CPC Class Codes: C04B 35/532 containing a carbonisable binder
• CPC Class Codes: C04B 35/62218 obtaining ceramic films, e.g. by using temporary supports
• CPC Class Codes: C04B 35/62635 Mixing details
• CPC Class Codes: C04B 35/6269 Curing of mixtures
• CPC Class Codes: C04B 35/83 Carbon fibres in a carbon matrix
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 4/13 Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
• CPC Class Codes: H01M 4/139 Processes of manufacture
• CPC Class Codes: H01M 4/362 Composites
• CPC Class Codes: H01M 4/38 of elements or alloys
• CPC Class Codes: H01M 4/386 : Silicon or alloys based on silicon
• CPC Class Codes: H01M 4/587 : for inserting or intercalating light metals
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product

Abstract

Composite materials and methods of forming composite materials are provided. The composite materials described herein can be utilized as an electrode material for a battery. In certain embodiments, the composite material includes greater than 0% and less than about 90% by weight silicon particles, and greater than 0% and less than about 90% by weight of one or more types of carbon phases. At least one of the one or more types of carbon phases can be a substantially continuous phase. The method of forming a composite material can include providing a mixture that includes a precursor and silicon particles, and pyrolysing the precursor to convert the precursor into one or more types of carbon phases to form the composite material.

Claims

1. A composite material comprising:

greater than 0% and less than about 90% by weight silicon particles;

greater than 0% and less than about 90% by weight of one or more types of carbon phases, wherein at least one of the one or more types of carbon phases is a substantially continuous phase.

2. The composite material of claim 1, wherein the silicon particles have an average largest dimension less than about 1 μ

m.

3. The composite material of claim 1, wherein the silicon particles comprise about 20% to about 80% by weight of the composite material.

4. The composite material of claim 1, wherein the at least one of the one or more types of carbon phases that is a substantially continuous phase is electrochemically active and electrically conductive.

5. The composite material of claim 1, wherein the at least one of the one or more types of carbon phases that is a substantially continuous phase comprises hard carbon.

6. The composite material of claim 1, wherein the one or more types of carbon phases comprises graphite particles.

7. The composite material of claim 1, further comprising conductive particles.

8. The composite material of claim 1, further comprising metal particles.

9. The composite material of claim 1, wherein the composite material is substantially electrochemically active.

10. The composite material of claim 1, wherein the composite material is self-supported.

11. A battery electrode comprising the composite material of claim 1.

12. A method of using the composite material of claim 1, comprising using the composite material only at a gravimetric capacity less than about 70% of a maximum gravimetric capacity of the composite material.

13. A method of forming a composite material comprising:

providing a mixture comprising a precursor and silicon particles; and

pyrolysing the precursor to convert the precursor into one or more types of carbon phases to form the composite material.

14. The method of claim 13, wherein after pyrolysing the precursor, the mixture forms a self-supported composite structure.

15. The method of claim 13, wherein at least one of the one or more types of carbon phases is a substantially continuous phase.

16. The method of claim 15, wherein the at least one of the one or more types of carbon phases that is a substantially continuous phase comprises hard carbon.

17. The method of claim 13, wherein the silicon particles comprise about 20% to about 80% by weight of the composite material.

18. The method of claim 13, wherein the mixture further comprises a solvent.

19. The method of claim 13, wherein the precursor comprises a polyimide.

20. The method of claim 13, wherein the precursor comprises a phenolic resin.

21. The method of claim 13, wherein the precursor comprises a hydrocarbon compound.

22. The method of claim 13, wherein the silicon particles comprise greater than 0% and less than about 80% by weight in the mixture and the precursor comprises about 5% to about 80% by weight in the mixture.

23. The method of claim 13, further comprising:

casting the mixture on a substrate;

drying the mixture to form a film;

removing the film from the substrate; and

curing the film in a hot press.

24. The method of claim 13, further comprising forming a battery electrode from the composite material.